Thin film transistor substrate and manufacturing method thereof

ABSTRACT

A TFT substrate includes a TFT including a source electrode having a lower source electrode and an upper source electrode, which are electrically connected to each other, and a drain electrode having a lower drain electrode and an upper drain electrode, which are electrically connected to each other. The lower source electrode and the lower drain electrode are in contact with a lower surface of the semiconductor film, and the upper source electrode and the upper drain electrode are in contact with an upper surface of the semiconductor film.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a thin film transistor substrate usedin a display device or the like.

2. Description of the Background Art

A TFT active matrix substrate (thin film transistor substrate;hereinafter referred to as a “TFT substrate”) using a thin filmtransistor (hereinafter referred to as a “TFT”) as a switching elementis used in an electrooptical device such as a display device (liquidcrystal display) using liquid crystal. A semiconductor device such as aTFT has features of reduced power consumption and thin size, and it hasactively been applied to a flat panel display that replaces a CRT(Cathode Ray Tube) by utilizing these features.

An electrooptical element for a liquid crystal display (LCD) includes asimple matrix LCD and a TFT-LCD using a TFT as a switching element. TheTFT-LCD is particularly more excellent than the CRT or the simple matrixLCD in portability and display quality, so that it has widely been putinto practical use such as a notebook personal computer.

In general, a TFT-LCD includes a liquid crystal display panel having aliquid crystal layer held therein between a TFT substrate having aplurality of TFTs arranged in an array and a counter substrate having acolor filter and the like. A polarization plate is provided on each of afront surface and a back surface of the liquid crystal display panel,and a backlight is further provided on one of these surfaces. Thisconfiguration can realize a satisfactory color display.

An LCD with an IPS (In Plane Switching) system that is a liquid crystaldriving system using a transverse electric field and attained byimproving a viewing angle of a conventional TFT-LCD has widely been usedfor a display device and the like by utilizing the feature of wideviewing angle. However, it also has problems of low opening ratio andlow transmittance on a pixel display portion, and it is difficult toattain a bright display characteristic. The main reason for this is thatan electric field for driving liquid crystal is not effectively appliedabove an interdigital pixel electrode used for the IPS-LCD, and hence,some liquid crystals on the pixel electrode do not operate. In order tosolve this problem, an LCD with an FFS (Fringe Field Switching) systemdescribed in Japanese Patent Application Laid-Open No. 2001-56474 hasbeen proposed.

A TFT substrate in a general FFS-LCD described in Japanese PatentApplication Laid-Open No. 2001-56474 is formed through at least sixphotolithography processes including (1) a process of forming a gateelectrode, (2) a process of forming a pixel electrode, (3) a process offorming a gate insulating film and a semiconductor film, (4) a processof forming source and drain electrodes, (5) a process of forming contactholes on a protection insulating film, and (6) a process of forming acommon electrode.

Amorphous silicon (Si) is conventionally used as a semiconductor filmserving as an active layer (channel layer) in a switching element in aTFT substrate for a liquid crystal display. Recently, development of aTFT using an oxide semiconductor for an active layer has been activelymade. An oxide semiconductor has mobility higher than that of aconventional amorphous silicon. As the oxide semiconductor, zinc oxide(ZnO) materials or amorphous InGaZnO materials formed by adding galliumoxide (Ga₂O₃) and indium oxide (In₂O₃) to zinc oxide are mainly used.This technique is described in Japanese Patent Application Laid-Open No.2005-77822, Japanese Patent Application Laid-Open No. 2007-281409, andKenji Nomura et al., “Room-temperature fabrication of transparentflexible thin-film transistors using amorphous oxide semiconductors”,Nature 2004, vol. 432, pages 488 to 492.

An oxide semiconductor material can be etched by a weak acid solutionsuch as oxalic acid or carboxylic acid, like an oxide conductor such asamorphous ITO (indium oxide (In₂O₃)+tin oxide (SnO₂)) that is atransparent conductor or amorphous InZnO (indium oxide (In₂O₃)+zincoxide (ZnO)), so that it has an advantage of easy pattern formation.

However, the oxide semiconductor material is easy to be dissolved evenin an acid solution used for an etching process of a metal film (Cr, Ti,Mo, Ta, Al, Cu, and an alloy of these metals) generally used for asource electrode or a drain electrode in a TFT. Accordingly, when a TFThaving a structure in which a source electrode and a drain electrode arearranged on an upper layer of an oxide semiconductor is manufactured asillustrated in FIG. 11 in Japanese Patent Application Laid-Open No.2007-281409, a selective etching in which only a metal film of thesource electrode and the drain electrode is etched and the oxidesemiconductor is not etched and left is difficult.

In order to solve this problem, it is considered that a TFT structureincluding a semiconductor film as an active layer formed on a sourceelectrode and a drain electrode is employed as illustrated in FIG. 1 inJapanese Patent Application Laid-Open No. 2003-92410 and FIG. 1A inJapanese Patent Application Laid-Open No. 2006-5329, for example. Inthis TFT structure, it is only necessary that, after the gate electrode,the source electrode, and the drain electrode are formed by processingthe metal film, the semiconductor film made of an oxide semiconductor isformed. Therefore, there is no chance that the semiconductor film isdissolved in an acid solution upon etching the metal film. In addition,since a weak acid solution such as oxalic acid or carboxylic acid usedupon etching the oxide semiconductor does not etch a normal metal, thesource electrode and the drain electrode are not etched during theformation of the semiconductor film. Accordingly, the selective etchingof the semiconductor film made of an oxide semiconductor and the metalfilm can be carried out, whereby a high-performance TFT substrate havinghigh mobility can be manufactured.

There is no problem in the case described in Japanese Patent ApplicationLaid-Open No. 2001-56474 in which the transparent conductive filmpattern becomes the uppermost layer. However, as described in JapanesePatent Application Laid-Open No. 08-6059 (1996), when an insulating film(hereinafter referred to as “upper insulating film”) such as aprotection film or an interlayer insulating film is formed on atransparent conductive film pattern, stress of the transparentconductive film and stress of the upper insulating film is unbalanced,so that a phenomenon called “film floating” or “film stripping”(hereinafter collectively referred to as “film floating”) in which theupper insulating film is peeled on the edge of the transparentconductive film pattern might occur. The film floating prominentlyoccurs on a region where the pattern density is relatively coarse, suchas on a frame region outside a display region, e.g., on an externalconnection terminal portion or a wiring conversion portion. Theoccurrence of the film floating deteriorates the function of the upperinsulating film as the protection film to cause corrosion, ordeteriorates the function of the interlayer insulating film to causebreakdown. Therefore, when the film floating occurs, yield of productsand reliability is deteriorated. In addition, the peeled upperinsulating film scatters in a manufacturing device to generate dust,which adversely affects other products manufactured by the samemanufacturing device. This also deteriorates yield of products andreliability.

On the other hand, when a film-forming condition that makes it difficultto cause the film floating due to the balanced stress is employed uponforming the upper insulating film, problems arise including a problem ofreduction in transmittance of the transparent conductive film pattern,and a problem of occurrence of connection failure between a line and apixel electrode due to a formation of a wedge-like gap (hereinaftermerely referred to as “wedge”) on an interface of a gate insulating filmand an interlayer insulating film in a contact hole connecting the lineand the pixel electrode. Particularly, in a liquid crystal displayhighly demanded to have high brightness (high open ratio and hightransmittance) and wide viewing angle, enhancement in transmittance of atransparent conductive film and an adoption of an FFS system areinevitable, which increases the case in which such a film-formingcondition as to be liable to generate the film floating in the upperinsulating film has to be employed.

In addition, in the FFS system, it is essential that a pixel electrodeand a common electrode both made of a transparent conductive film arearranged opposite to each other via an interlayer insulating film, sothat the interlayer insulating film (upper insulating film) isunavoidably arranged on at least one of the transparent electrodes.Therefore, a countermeasure for the film-floating problem has to bedevised.

When a film made of an oxide semiconductor such as ZnO or InGaZnO isdirectly formed on a metal film (Cr, Ti, Cu, Mo, Ta, Al, or an ally ofthese metals) serving as a source electrode or a drain electrode of aTFT by using a sputtering method or a vacuum deposition method, an oxidelayer of the metal film is formed on the interface between both filmsdue to an interface reaction, whereby the electric resistance (interfaceresistance) increases.

According to experiments conducted by the present inventors, when ametal film made of Al is formed on an oxide semiconductor film made ofInGaZnO (ratio of number of atoms: In:Ga:Zn:O=1:1:1:4), for example, aninterface resistance value per an area of 50 μm×50 μm is 200 kΩ, whilean interface resistance value per the same area is 100 MΩ or more, whenthe formation order of the Al film and the InGaZnO film is reversed. Asfor other metals (Cr, Ti, Cu, Mo, Ta), the interface resistance valueincreases in single or more digits, when the formation order of themetal film and the InGaZnO film is reversed, as in the case of Al. Thesame applies to the case where an alloy film having these metal films asa main component (the component having the highest ratio of number ofcontained atoms) is used.

On the other hand, a reduction reaction with the metal film occurs onthe oxide semiconductor film, so that an oxide semiconductor film withinsufficient oxygen is generated on the channel surface near theinterface. In the oxide semiconductor film with insufficient oxygen, thecarrier density increases to reduce resistance, which entails a problemof an increase in off current of the TFT. In the TFT structure in whichthe semiconductor film made of the oxide semiconductor is formed on thesource electrode and the drain electrode, which are made of the metalfilm, the interface reaction layer increases. Consequently, thedeterioration in on/off performance of the TFT and the reduction inmobility are generated, which entails a problem of deterioration in TFTcharacteristic.

SUMMARY OF THE INVENTION

An object of the present invention is to obtain satisfactory connectionproperty between a semiconductor layer and source/drain electrodes in aTFT substrate that includes a TFT using an oxide semiconductor for asemiconductor film and is driven by using a transverse electric field,to prevent film floating of an insulating film on a transparentconductive film, and to suppress interface reaction between thesemiconductor film and source and drain electrodes.

A thin film transistor substrate according to the present inventionincludes a gate electrode and an auxiliary capacitance electrode, whichare formed on a substrate, and a first insulating film formed to coverthe gate electrode and the auxiliary capacitance electrode. A lowersource electrode, a lower drain electrode, and a pixel electrodeconnected to the lower drain electrode are formed on the firstinsulating film. A semiconductor film electrically connected to thelower source electrode and the lower drain electrode is formed on thelower source electrode and the lower drain electrode. A secondinsulating film is formed on the lower source electrode, the lower drainelectrode, and the semiconductor film. An upper source electrodeelectrically connected to the semiconductor film and the lower sourceelectrode through a contact hole, an upper drain electrode electricallyconnected to the semiconductor film and the lower drain electrodethrough a contact hole, and a common electrode electrically connected tothe auxiliary capacitance electrode through a contact hole are formed onthe second insulating film.

Since the source electrode and the drain electrode are electricallyconnected to upper and lower surfaces of the semiconductor film, acontact area with the semiconductor film increases, whereby an interfaceresistance can be reduced. Even if a failure in the interface resistanceoccurs on one of the surfaces of the semiconductor layer, this failurecan be compensated on the other surface. Therefore, occurrence of defectcaused by characteristic defect of the thin film transistor can beprevented.

In particular, a TFT substrate having high operating speed and a displaydevice using the TFT substrate can be manufactured with good yield byusing an oxide semiconductor having high mobility for a semiconductorfilm. Accordingly, a high-performance TFT substrate and a liquid crystaldisplay can be manufactured with good productivity.

These and other objects, features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of the present invention when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view for schematically describing an overall structureof a TFT substrate;

FIG. 2 is a view illustrating a planar configuration of a pixel of theTFT substrate according to a first preferred embodiment;

FIG. 3 is a view illustrating a sectional configuration of the pixel ofthe TFT substrate according to the first preferred embodiment;

FIGS. 4 to 7 are sectional views illustrating a manufacturing process ofthe TFT substrate according to the first preferred embodiment;

FIG. 8 is a view illustrating a planar configuration of a pixel of a TFTsubstrate according to a second preferred embodiment;

FIG. 9 is a view illustrating a sectional configuration of the pixel ofthe TFT substrate according to the second preferred embodiment;

FIGS. 10 to 15 are sectional views illustrating a manufacturing processof the TFT substrate according to the second preferred embodiment;

FIG. 16 is a view illustrating a planar configuration of a pixel of aTFT substrate according to a third preferred embodiment;

FIG. 17 is a view illustrating a sectional configuration of the pixel ofthe TFT substrate according to the third preferred embodiment; and

FIGS. 18 to 23 are sectional views illustrating a manufacturing processof the TFT substrate according to the third preferred embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENTS First Preferred Embodiment

FIG. 1 is a plan view illustrating a configuration of a TFT substrateaccording to a first preferred embodiment. The TFT substrate accordingto the first preferred embodiment is an active matrix substrateincluding a plurality of thin film transistors (TFTs), which serve as aswitching element and are arranged in a matrix. In the present preferredembodiment, the TFT substrate for a liquid crystal display (LCD) that isa planar display device (flat panel display) will be described as oneexample.

A TFT substrate 200 is divided into a display region 202 in which pixels204, each having a TFT 201, are arranged in a matrix and a frame region203 externally enclosing the display region 202.

A plurality of gate lines (scanning signal lines) 3 and a plurality ofsource lines (display signal lines) 9 are arranged on the display region202. The plurality of gate lines 3 are arranged parallel to one another,and the plurality of source lines 9 are also arranged parallel to oneanother. The plurality of gate lines 3 and the plurality of source lines9 cross each other. In FIG. 1, the gate lines 3 extend in the horizontaldirection, and the source lines 9 extend in the longitudinal direction.The region enclosed by the adjacent gate line 3 and the adjacent sourceline 9 is specified as the pixel 204. Therefore, the pixels 204 arearranged in a matrix in the display region 202.

In FIG. 1, one pixel 204 is representatively illustrated as enlarged. Atleast one TFT 201 is arranged on the pixel 204. The TFT 201 is arrangedin the vicinity of the crossing point of the source line 9 and the gateline 3, and includes a gate electrode connected to the gate line 3, asource electrode connected to the source line 9, and a drain electrodeconnected to a pixel electrode 11. The pixel electrode 11 formsauxiliary capacitance 209 with an auxiliary capacitance electrode 5, inwhich the auxiliary capacitance electrode 5 is connected to an auxiliarycapacitance line 210 to which a predetermined common potential issupplied. The auxiliary capacitance line 210 extends parallel to thegate line 3 (orthogonal to the source line 9), and the gate line 3 andthe auxiliary capacitance line 210 are alternately arranged.

On the other hand, a scanning signal drive circuit 205 and a displaysignal drive circuit 206 are provided on the frame region 203 of the TFTsubstrate 200. Although not illustrated, the gate line 3 is extractedfrom the display region 202 to the frame region 203 on the side wherethe scanning signal drive circuit 205 is provided, and connected to thescanning signal drive circuit 205. Similarly, the source line 9 isextracted from the display region 202 to the frame region 203 on theside where the display signal drive circuit 206 is provided, andconnected to the display signal drive circuit 206.

A connection substrate 207 for connecting the scanning signal drivecircuit 205 to the outside is provided in the vicinity of the scanningsignal drive circuit 205, while a connection substrate 208 forconnecting the display signal drive circuit 206 to the outside isprovided in the vicinity of the display signal drive circuit 206. Theseconnection substrates 207 and 208 are wiring boards such as an FPC(Flexible Printed Circuit), for example.

Various control signals are externally supplied to the scanning signaldrive circuit 205 via the connection substrate 207, while variouscontrol signals and image data are externally supplied to the displaysignal drive circuit 206 via the connection substrate 208. The scanningsignal drive circuit 205 supplies a gate signal (scanning signal) to thegate line 3 based upon the external control signal. The gate line 3 isselected, one by one, in a predetermined cycle based upon the gatesignal. The display signal drive circuit 206 supplies a display signalaccording to the image data to the source line 9 based upon the externalcontrol signal. According to the operations of the scanning signal drivecircuit 205 and the display signal drive circuit 206, a display voltageaccording to the display signal is supplied to each pixel 204.

The scanning signal drive circuit 205 and the display signal drivecircuit 206 are not limited to be provided on the TFT substrate 200, andthey may be formed by using a TCP (Tape Carrier Package) and may beconnected to the TFT substrate 200. As described later, the auxiliarycapacitance electrode 5 is arranged to be overlapped (superimposed) onthe pixel electrode 11 in plan view to form the auxiliary capacitance209 having the pixel electrode 11 as one electrode and the auxiliarycapacitance electrode 5 as another electrode. The auxiliary capacitanceelectrode 5 in each pixel 204 is connected to the auxiliary capacitanceline 210 to be bundled, and a predetermined common potential is suppliedthereto from the scanning signal drive circuit 205 or the display signaldrive circuit 206, for example.

The TFT 201 functions as a switching element for supplying the displayvoltage to the pixel electrode 11, and controlled to be on/off by thegate signal applied to the gate electrode from the gate line 3. When theTFT 201 is turned on, the display voltage supplied to the drainelectrode from the source line 9 is applied to the pixel electrode 11,whereby an electric field according to the display voltage is generatedbetween the pixel electrode 11 and a common electrode (not illustrated).Capacitance (liquid crystal capacitance) parallel with the auxiliarycapacitance 209 is formed between the pixel electrode 11 and the commonelectrode via the liquid crystal. The display voltage applied to thepixel electrode 11 is held for a certain period of time by the liquidcrystal capacitance and the auxiliary capacitance 209.

In the case of a liquid crystal display, a counter substrate is arrangedopposite to the TFT substrate 200. The counter substrate is a colorfilter substrate, for example, and arranged on the front surface(recognizable side) of the TFT substrate. The counter substrate isprovided with a color filter, a black matrix (BM), and an orientationfilm, for example. The orientation film may also be formed on thesurface of the TFT substrate 200. In a liquid crystal display driven byusing a transverse electric field as in an FFS (Fringe Field Switching)system, the common electrode is arranged on the TFT substrate 200, noton the counter substrate.

The TFT substrate 200 and the counter substrate are adhered with a fixedgap (cell gap), and the liquid crystal fills the gap to be sealed,whereby a liquid crystal display panel is formed. Specifically, theliquid crystal display panel has a structure in which a liquid crystallayer is held between the TFT substrate 200 and the counter substrate.In addition, a polarizing plate, a wave plate, and the like are providedon the outer surface of the liquid crystal display panel. A backlightunit is provided on the back surface (the backside of the TFT substrate200) of the liquid crystal display panel.

An operation of the liquid crystal display will briefly be described.The liquid crystal held between the TFT substrate 200 and the countersubstrate is driven (the orientation direction thereof is controlled) bythe electric field generated between the pixel electrode 11 and thecommon electrode. When the orientation direction of the liquid crystalchanges, the polarizing state of light passing through the liquidcrystal changes. Therefore, light from the backlight unit having passedthrough the polarizing plate and converted into linearly polarized lightchanges the polarized state when passing through the liquid crystallayer of the liquid crystal display panel. Specifically, the light fromthe backlight unit becomes linearly polarized light by the polarizingplate close to the TFT substrate 200. The linearly polarized lightchanges the polarized state by passing through the liquid crystal layer.

In the light passing through the liquid crystal layer, the quantity oflight passing through the polarizing plate close to the countersubstrate is changed depending on the polarized state. Specifically, inthe light being transmitted through the liquid crystal display panelfrom the backlight unit, the quantity of light passing through thepolarizing plate on the recognizable side changes. The orientationdirection of the liquid crystal changes according to the display voltageapplied to the pixel electrode 11. Therefore, the quantity of lightpassing through the polarizing plate on the recognizable side can becontrolled by controlling the display voltage. The liquid crystaldisplay displays a desired image by controlling the display voltage,applied to each pixel, based upon the display data.

Next, the detailed structure of the TFT substrate 200 according to thepresent preferred embodiment will be described with reference to FIGS. 2and 3. FIG. 2 is a view illustrating a planar configuration of anessential part including the pixel 204 on the TFT substrate 200 usingthe FFS system, and FIG. 3 is a view illustrating its sectionalconfiguration. FIG. 3 illustrates the sections corresponding to X-Xline, Y-Y line, and Z-Z line in FIG. 2. The section along X-X linecorresponds to a formation region of the pixel 204 (pixel portion). Thesection along Y-Y line corresponds to a formation region of the gateterminal 4 and a gate terminal pad 25 (gate terminal portion) forsupplying the gate signal to the gate line 3. The section along Z-Z linecorresponds to a formation region of the source terminal 10 and a sourceterminal pad 26 (source terminal portion) for applying the displaysignal to the source line 9.

The section of the pixel portion along X-X line includes a “gate/sourceline crossing portion” where the gate line 3 and the source line 9 crosseach other, a “TFT portion” that is a formation region of the TFT 201, a“transmissive pixel portion” that is a formation region of the pixelelectrode 11 and the common electrode 27, and an “auxiliary capacitanceportion” that is a formation region of the auxiliary capacitance 209, asillustrated in FIG. 3.

As illustrated in FIG. 3, the TFT substrate 200 is formed by using asubstrate 1 that is a transparent insulating substrate made of a glass,for example. The gate line 3, the gate electrode 2, the auxiliarycapacitance electrode 5, the auxiliary capacitance line 210, and thegate terminal 4 are formed on the substrate 1. An insulating film 6 isformed to cover these components. Since the insulating film 6 functionsas a gate insulating film on the TFT portion, it is referred to as a“gate insulating film” below.

In FIG. 2, the gate line 3 extends in the horizontal direction. The gateelectrode 2 on the TFT 201 is a part of the gate line 3. Specifically,the portion of the gate line 3 on the TFT portion serves as the gateelectrode 2. The gate electrode 2 has a width larger than that of theother portion of the gate line 3. The gate terminal 4 is formed on oneend of the gate line 3. The auxiliary capacitance line 210 extendsparallel to the gate line 3, and a part thereof serves as the auxiliarycapacitance electrode 5.

As illustrated in FIG. 3, on the TFT substrate 200 according to thepresent preferred embodiment, each of the source line 9, the sourceelectrode 7, and the drain electrode 8 includes two layers, which areupper and lower layers, sandwiching a protection insulating film 14.Specifically, the source line 9 includes a lower source line 9 a and anupper source line 9 b, the source electrode 7 includes a lower sourceelectrode 7 a and an upper source electrode 7 b, and the drain electrode8 includes a lower drain electrode 8 a and an upper drain electrode 8 b.

The lower source line 9 a, the lower source electrode 7 a, the lowerdrain electrode 8 a, the pixel electrode 11, and the source terminal 10are formed on the gate insulating film 6. The lower source electrode 7 aand the lower drain electrode 8 a are formed to be superimposed on thegate electrode 2, but are arranged to be separated from each other. Achannel region of the TFT 201 is formed on the region between the lowersource electrode 7 a and the lower drain electrode 8 a.

In FIG. 2, the source line 9 (the lower source line 9 a and the uppersource line 9 b) extends in the longitudinal direction. The lower sourceelectrode 7 a is formed to be connected to the lower source line 9 a.Specifically, the portion branched from the lower source line 9 a andextending to the TFT portion serves as the lower source electrode 7 a.

The pixel electrode 11 is a plate electrode, and formed to be connectedto the lower drain electrode 8 a. Specifically, the portion of the pixelelectrode 11 superimposed on the gate electrode 2 serves as the lowerdrain electrode 8 a. The pixel electrode 11 is also locally superimposedon the auxiliary capacitance electrode 5 via the gate insulating film 6,and the auxiliary capacitance 209 is formed on this portion. In thetransmissive liquid crystal display, the pixel electrode 11 is made of atranslucent conductive film.

A semiconductor film 12 is formed to extend over the lower sourceelectrode 7 a and the lower drain electrode 8 a (i.e., the semiconductorfilm 12 is also formed on the region between the lower source electrode7 a and the lower drain electrode 8 a). The lower surface of thesemiconductor film 12 is in contact with the lower source electrode 7 aand the lower drain electrode 8 a, whereby the lower source electrode 7a and the lower drain electrode 8 a are both electrically connected tothe semiconductor film 12. The semiconductor film 12 is formed in anisland shape, and the portion located between the lower source electrode7 a and the lower drain electrode 8 a serves as the channel region 13.

In the present preferred embodiment, an oxide semiconductor is used asthe semiconductor film 12. More specifically, examples of a usable oxidesemiconductor include an oxide semiconductor of zinc oxide (ZnO), and anInGaZnO oxide semiconductor formed by adding gallium oxide (Ga₂O₃) andindium oxide (In₂O₃) to zinc oxide (ZnO). Since the channel region 13 ofthe semiconductor film 12 is made of the oxide semiconductor, mobilityhigher than that of a semiconductor film using amorphous silicon can berealized.

The protection insulating film 14 is formed on the entire upper surfaceof the substrate 1 so as to cover the semiconductor film 12, the lowersource line 9 a, the lower source electrode 7 a, the lower drainelectrode 8 a, the pixel electrode 11, and the source terminal 10. Thechannel region 13 of the TFT 201 is protected by the protectioninsulating film 14.

A plurality of contact holes are formed on the protection insulatingfilm 14. Specifically, the contact holes are a contact hole 16 reachingthe lower source line 9 a, contact holes 15 and 17 reaching thesemiconductor film 12, a contact hole 18 reaching the lower drainelectrode 8 a, a contact hole 21 reaching the auxiliary capacitance line210, a contact hole 19 reaching the gate terminal 4, and a contact hole20 reaching the source terminal 10 (the contact holes 19 and 21penetrates not only the protection insulating film 14 but also the gateinsulating film 6).

The contact hole 15 is formed on the position where it is superimposedon the lower source electrode 7 a, and the contact hole 17 is formed onthe position where it is superimposed on the lower drain electrode 8 a.Accordingly, the contact holes 15 and 17 are formed on the positionswhere they are not superimposed on the channel region 13. The contactholes 16 are formed along the source line 9 with a constant interval asillustrated in FIG. 2.

The upper source line 9 b, the upper source electrode 7 b, the upperdrain electrode 8 b, the common electrode 27, the gate terminal pad 25,and the source terminal pad 26 are formed on the protection insulatingfilm 14.

The upper source electrode 7 b is formed to be connected to the uppersource line 9 b. Specifically, the portion branched from the uppersource line 9 b and extending to the TFT portion serves as the lowersource electrode 7 a. The upper source line 9 b is in contact with thelower source line 9 a through the contact hole 16, whereby the lowersource line 9 a and the upper source line 9 b are electricallyconnected. The upper source electrode 7 b is in contact with thesemiconductor film 12 above the lower source electrode 7 a through thecontact hole 15, whereby the semiconductor film 12 and the upper sourceelectrode 7 b are electrically connected. Accordingly, the semiconductorfilm 12 and the source line 9 are electrically connected through thelower source electrode 7 a, and electrically connected through the uppersource electrode 7 b.

The upper drain electrode 8 b is in contact with the semiconductor film12 above the lower drain electrode 8 a through the contact hole 17,whereby the semiconductor film 12 and the upper drain electrode 8 b areelectrically connected. The upper drain electrode 8 b is also in contactwith the lower drain electrode 8 a through the contact hole 18, wherebythe lower drain electrode 8 a and the upper drain electrode 8 b areelectrically connected. Accordingly, the semiconductor film 12 and thepixel electrode 11 are electrically connected through the lower drainelectrode 8 a, and also electrically connected through the upper drainelectrode 8 b.

As illustrated in FIG. 2, the common electrode 27 is an interdigitalelectrode having a slit, and is arranged opposite to the pixel electrode11 via the protection insulating film 14. The common electrode 27 is incontact with the auxiliary capacitance line 210 through the contact hole21, whereby the common electrode 27 and the auxiliary capacitance line210 are electrically connected.

The gate terminal pad 25 is in contact with the gate terminal 4 throughthe contact hole 19, whereby the gate terminal pad 25 and the gateterminal 4 are electrically connected. The source terminal pad 26 is incontact with the source terminal 10 through the contact hole 20, wherebythe gate terminal pad 25 and the source terminal 10 are electricallyconnected.

Subsequently, a manufacturing method of the TFT substrate 200 accordingto the first preferred embodiment will be described with reference toFIGS. 4 to 7. The components in FIGS. 4 to 7 corresponding to thecomponents in FIG. 3 are identified by the same numerals.

Firstly, the substrate 1 is cleaned with cleaning liquid or pure water.In the present preferred embodiment, a glass substrate with a thicknessof 0.5 mm is used as the substrate 1. Then, a first conductive film thatis a material of the gate electrode 2 and the gate line 3 is formed onthe entire main surface of the cleaned substrate 1.

Examples of usable first conductive film include chrome (Cr), molybdenum(Mo), titanium (Ti), copper (Cu), tantalum (Ta), tungsten (W), aluminum(Al), and an alloy formed by adding a small amount of other elements tothese metals. The first conductive film may have a stacked structureincluding two or more layers made of these metals or alloy. Alow-resistance conductive film having a specific resistance value of notmore than 50 μΩcm can be formed by using these metals or alloy.

In the present preferred embodiment, an Mo film is used as the firstconductive film, and this Mo film is subjected to film formation to havea thickness of 200 nm by a sputtering method using Ar gas. Thereafter, aphotoresist material is applied on the Mo film to form a photoresistpattern by the first photolithography process, and then, the Mo film ispatterned by an etching process with the photoresist pattern being usedas a mask. In this preferred embodiment, wet etching using a solution(PAN chemical) containing phosphoric acid, acetic acid, and nitric acidis performed.

Thereafter, the photoresist pattern is removed. As a result, the gateline 3, the gate electrode 2, the auxiliary capacitance electrode 5, theauxiliary capacitance line 210, and the gate terminal 4 are formed onthe substrate 1 as illustrated in FIG. 4.

Next, the gate insulating film 6 is formed on the entire upper surfaceof the substrate 1. In the present preferred embodiment, an oxidesilicon film (SiO) serving as the gate insulating film 6 is formed byusing a chemical vapor deposition (CVD) method. In the present preferredembodiment, the oxide silicon film with a thickness of 300 nm is formedunder a substrate heating condition of about 300° C. Since the oxidesilicon film has low barrier property (blocking property) to impurityelements affecting the TFT characteristic, such as water content (H₂O),hydrogen (H₂), sodium (Na), and potassium (K), the gate insulating film6 may have a stacked structure including a nitride silicon film (SiN),which has excellent barrier property, as a lower layer of the oxidesilicon film, for example.

Thereafter, a second conductive film that is a material for the lowersource electrode 7 a, the lower drain electrode 8 a, and the pixelelectrode 11 is formed on the gate insulating film 6. In a transmissiveliquid crystal display, a translucent pixel electrode 11 has to beformed. Therefore, a translucent conductive film is used as the secondconductive film.

In the present preferred embodiment, an ITO film (a mixture ratio ofindium oxide In₂O₃ and tin oxide SnO₂ is 90:10 (wt %), for example) isused as the second conductive film. An ITO film generally has a stablecrystal (polycrystalline) structure at room temperature. Here, the ITOfilm is formed with a sputtering method by using a gas containinghydrogen (H) into argon (Ar), e.g., a gas formed by mixing hydrogen (H₂)gas or water vapor (H₂O), whereby the ITO film with a thickness of 100nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the second photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using an oxalic acid solution can be usedfor this etching process.

Thereafter, the photoresist pattern is removed. As a result, the lowersource line 9 a, the lower source electrode 7 a, the lower drainelectrode 8 a, the pixel electrode 11, and the source terminal 10 areformed as illustrated in FIG. 5.

Then, the substrate 1 is heated at a temperature of 200° C. According tothis heat treatment, the ITO film in the amorphous state is crystallizedto become a polycrystalline ITO film. Since the ITO film in apolycrystalline state has excellent chemical stability, and is notdissolved into general etching chemical (containing oxalic acid) exceptfor aqua regia (hydrochloric acid+nitric acid), etching selectivity witha metal film formed thereon in the subsequent process can be assured.The temperature in the heat treatment for crystallizing the amorphousITO film has to be higher than at least a temperature (crystallizationtemperature) at which the crystallization of the amorphous ITO film isstarted. The crystallization temperature of an amorphous ITO film havinga general composition is about 150° C.

Next, an oxide semiconductor that is a material for the semiconductorfilm 12 is formed. In the present preferred embodiment, an oxide(InGaZnO) containing In, Ga, and Zn is used as the oxide semiconductor.Here, an InGaZnO target having an atomic composition ratio of In:Ga:Zn:Ois 1:1:1:4 is used, and the oxide semiconductor (InGaZnO film) is formedby a sputtering method using Ar gas.

In this case, the atomic composition ratio of oxygen is less than astoichiometric composition, so that an oxide film with insufficientoxygen ion (in the example described above, the composition ratio of Ois less than 4) is generally formed. Therefore, it is preferable thatthe sputtering is performed by adding oxygen gas (O₂) to Ar gas. In thepresent preferred embodiment, the InGaZnO film with a thickness of 50 nmis formed with the sputtering using a mixed gas formed by adding O₂ gasof 10% in a partial pressure percent to Ar gas. The InGaZnO film isformed to have an amorphous structure. The crystallization temperatureof the InGaZnO film having the amorphous structure is generally 500° C.or higher, so that the most part in the film keeps the amorphousstructure and is stabilized in this state at room temperature.

Next, a photoresist pattern is formed by the third photolithographyprocess, and the InGaZnO film is etched by using this pattern as a mask.Thereafter, the photoresist pattern is removed. As a result, thesemiconductor film 12 extending over the lower source electrode 7 a andthe lower drain electrode 8 a is formed as illustrated in FIG. 6.

During the etching process of the InGaZnO film having the amorphousstructure, wet etching using an oxalic acid solution can be employed.The lower source line 9 a, the lower source electrode 7 a, the lowerdrain electrode 8 a, the pixel electrode 11, and the source terminal 10,which are formed in the previous process, are the crystallized ITO film,and they are not etched by the oxalic acid solution. Therefore, thesepatterns are not eliminated.

The semiconductor film 12 made of the oxide semiconductor (InGaZnO film)is brought into contact with the lower source electrode 7 a and theupper source electrode 7 b made of ITO that is also the oxide in orderto electrically connect the semiconductor film 12 and the lower andupper source electrodes 7 a and 7 b. According to this configuration,the interface reaction (oxidation-reduction reaction) between thesemiconductor film 12 and the lower and upper source electrodes 7 a and7 b is prevented. Accordingly, the contact resistance (interfaceresistance) between the semiconductor film 12 and the lower and uppersource electrodes 7 a and 7 b can be suppressed low. Consequently, oncurrent and mobility of the TFT 201 can be increased, whereby an effectof enhancing the TFT characteristic can be obtained.

After the semiconductor film 12 is formed, the protection insulatingfilm 14 is formed on the entire upper surface of the substrate 1. In thepresent preferred embodiment, an oxide silicon (SiO) film with athickness of 300 nm is formed by using a chemical vapor deposition (CVD)method under the substrate heating condition of about 250° C.

A photoresist pattern is then formed by the fourth photolithographyprocess, and the protection insulating film 14 and the gate insulatingfilm 6 are etched by using this pattern as a mask, whereby the contactholes 15 to 21 are simultaneously formed. A dry etching process usingfluorine gas can be used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the contacthole 16 reaching the lower source line 9 a, the contact holes 15 and 17reaching the semiconductor film 12, the contact hole 18 reaching thelower drain electrode 8 a, the contact hole 21 reaching the auxiliarycapacitance line 210, the contact hole 19 reaching the gate terminal 4,and the contact hole 20 reaching the source terminal 10 are formed asillustrated in FIG. 7.

In the present preferred embodiment, the protection insulating film 14is the oxide silicon film. However, the protection insulating film 14may have a stacked structure including a nitride silicon film, which hasexcellent barrier property, as an upper layer of the oxide silicon film,for example, since the oxide silicon film has low barrier property(blocking property) to impurity elements affecting the TFTcharacteristic, such as water content (H₂O), hydrogen (H₂), sodium (Na),and potassium (K). Alternatively, the protection insulating film 14 mayhave a single-layer structure of a silicon nitride film.

When the silicon nitride is used for the protection insulating film 14,a wedge might be formed during the formation of the contact holereaching the surface of the translucent conductive film by the dryetching using fluorine gas, and this wedge might cause an electricalconnection failure. The effective structure for preventing thegeneration of the wedge is such that the protection insulating film 14is formed to have a stacked structure having at least two layersincluding an upper silicon nitride film and a lower silicon nitridefilm, in which the lower silicon nitride film is formed to have asmaller absolute value of a film stress than the upper silicon nitridefilm. Specifically, the absolute value of the film stress of the lowersilicon nitride film is preferably set in the range of 150 MPa to 200MPa. When the N/Si ratio of the silicon nitride film is increased, theabsolute value of the film stress can be decreased, but the N/Si ratioof the upper silicon nitride film is desirably in the range of 1.1 to1.5. Alternatively, it is also effective that the protection insulatingfilm 14 is formed to have a single-layer structure of a silicon nitridefilm having a small absolute value of a film stress.

Since the generation of the wedge is prevented, stress is balancedduring the formation of the protection insulating film 14, whereby thefilm-forming condition that makes it difficult to generate the filmfloating is easy to be employed. Consequently, the film floating of theprotection insulating film 14 can be prevented.

Thereafter, a third conductive film that is the material for the uppersource electrode 7 b, the upper drain electrode 8 b, and the commonelectrode 27 is formed. In the present preferred embodiment, atranslucent conductive film is formed as the third conductive film. AnITO film (a mixture ratio of indium oxide In₂O₃ and tin oxide SnO₂ is90:10 (wt %), for example) is used as the translucent conductive film.An ITO film generally has a stable crystal (polycrystalline) structureat room temperature. Here, the ITO film is formed with a sputteringmethod by using a gas containing hydrogen (H) into argon (Ar), e.g., agas formed by mixing hydrogen (H₂) gas or water vapor (H₂O), whereby theITO film with a thickness of 100 nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the fifth photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using a solution containing phosphoricacid+nitric acid+acetic acid is used for this etching process. In thiscase, since the semiconductor film 12 made of the oxide semiconductorformed in the previous process is covered by the protection insulatingfilm 14, the pattern of the semiconductor film 12 is not eliminated bythe etching for the translucent conductive film, whereby the selectiveetching can be carried out.

Thereafter, the photoresist pattern is removed. As a result, the uppersource line 9 b, the upper source electrode 7 b, the upper drainelectrode 8 b, the common electrode 27, the gate terminal pad 25, andthe source terminal pad 26 are formed. Thus, the structure illustratedin FIG. 3 is completed.

As described above, in the first preferred embodiment, thehigh-performance TFT substrate 200 in which the oxide semiconductor isused for the semiconductor film 12 in the TFT 201 can be formed by fivephotolithography processes.

Upon assembling the liquid crystal display panel, an orientation filmand a spacer are formed on the surface of the completed TFT substrate200. The orientation film is a film for arraying the liquid crystal, andit is made of polyimide. A counter substrate that is separately formedto have a color filter or an orientation film is adhered to the TFTsubstrate 200. In this case, a gap is formed between the TFT substrate200 and the counter substrate by the spacer. The liquid crystal fillsthis gap, whereby the liquid crystal display panel is completed.Finally, a polarizing plate, a wave plate, and a backlight unit arearranged outside the liquid crystal display panel. Thus, a liquidcrystal display is completed.

In the present preferred embodiment, the semiconductor film 12 made ofan oxide semiconductor having weak chemical resistance is formed afterthe formation of the lower source electrode 7 a and the lower drainelectrode 8 a, and further, the ITO film that is the crystallized oxidetranslucent conductive film is used for the lower source electrode 7 aand the lower drain electrode 8 a. According to this structure, thesemiconductor film 12 that is the oxide semiconductor film canselectively be etched. In addition, the semiconductor film 12 and thelower source electrode 7 a as well as the lower drain electrode 8 a,which are made of oxide, are brought into contact with each other,whereby the semiconductor film 12 and the lower source electrode 7 a,and the semiconductor film 12 and the lower drain electrode 8 a areelectrically connected. Accordingly, the interface reaction(oxidation-reduction reaction) of these components can be prevented, andthe interface resistance can be suppressed low.

After the formation of the semiconductor film 12, the protectioninsulating film 14 is formed to cover the semiconductor film 12 that isthe oxide semiconductor film, and the semiconductor film 12 and theupper source electrode 7 b as well as the upper drain electrode 8 b areelectrically connected through the contact holes 15 and 17 formed on theprotection insulating film 14. Specifically, the source electrode 7 andthe drain electrode 8 are electrically connected to both the upper andlower surfaces of the semiconductor film 12. Accordingly, even if theinterface resistance between the semiconductor film 12 and the sourceelectrode 7 or the drain electrode 8 is defective on one of the surfacesof the semiconductor film 12, such defect can be compensated on theother surface. Consequently, the interface resistance can further bereduced, and the occurrence of defect caused by characteristic defect ofthe TFT 201 can be prevented.

In addition, the source line 9 includes two layers that are the lowersource line 9 a and the upper source line 9 b, in which the lower sourceline 9 a and the upper source line 9 b are electrically connected by theplurality of contact holes 16 formed on the protection insulating film14 with a predetermined interval. Therefore, even if disconnectionoccurs on one of two layers, this can be compensated by the other one.Accordingly, the generation of defect caused by the disconnection of thesource line 9 can be prevented.

As described above, according to the present preferred embodiment, theinterface resistance between the semiconductor film 12 and the sourceelectrode 7 as well as the drain electrode 8 can be suppressed low, andthe generation of defect caused by the pattern failures of the lines caneffectively be prevented, even when an oxide semiconductor is used asthe semiconductor film 12 (channel layer) in the TFT 201. Since theoxide semiconductor having high mobility is used for the semiconductorfilm 12 in the TFT 201, the TFT substrate 200 having high operationspeed and a display device using the same can be manufactured with highyield. In other words, a high-performance TFT substrate and a liquidcrystal display can be manufactured with good productivity.

Second Preferred Embodiment

FIGS. 8 and 9 are views illustrating a configuration of a TFT substrate200 according to a second preferred embodiment. In these drawings, thecomponents same as those in FIGS. 2 and 3 are identified by the samenumerals.

FIG. 8 is a view illustrating a planar configuration of an essentialpart including a pixel 204 on the TFT substrate 200 using the FFSsystem, and FIG. 9 is a view illustrating its sectional configuration.FIG. 9 illustrates the sections corresponding to X-X line, Y-Y line, andZ-Z line in FIG. 8.

The section along X-X line corresponds to a formation region of thepixel 204 (pixel portion). The section along Y-Y line corresponds to aformation region of a gate terminal 4 and a gate terminal pad 25 (gateterminal portion), and the section along Z-Z line corresponds to aformation region of a source terminal 10 and a source terminal pad 26(source terminal portion). In addition, the section of the pixel portionalong X-X line includes a “gate/source line crossing portion” where agate line 3 and a source line 9 cross each other, a “TFT portion” thatis a formation region of the TFT 201, a “transmissive pixel portion”that is a formation region of a pixel electrode 11 and a commonelectrode 27, and an “auxiliary capacitance portion” that is a formationregion of auxiliary capacitance 209.

As illustrated in FIG. 9, the TFT substrate 200 is formed by using asubstrate 1 that is a transparent insulating substrate made of a glass,for example. The gate line 3, a gate electrode 2, an auxiliarycapacitance electrode 5, an auxiliary capacitance line 210, and the gateterminal 4 are formed on the substrate 1. A gate insulating film 6 isformed to cover these components.

In FIG. 8, the gate line 3 extends in the horizontal direction. The gateelectrode 2 on the TFT 201 is a part of the gate line 3. Specifically,the portion of the gate line 3 on the TFT portion serves as the gateelectrode 2. The gate electrode 2 has a width larger than that of theother portion of the gate line 3. The gate terminal 4 is formed on oneend of the gate line 3. The auxiliary capacitance line 210 extendsparallel to the gate line 3, and a part thereof serves as the auxiliarycapacitance electrode 5.

As illustrated in FIG. 9, on the TFT substrate 200 according to thepresent preferred embodiment, each of the source line 9, a sourceelectrode 7, and a drain electrode 8 includes two layers, which areupper and lower layers, sandwiching a protection insulating films 14 and30. Specifically, the source line 9 includes a lower source line 9 a andan upper source line 9 b, the source electrode 7 includes a lower sourceelectrode 7 a and an upper source electrode 7 b, and the drain electrode8 includes a lower drain electrode 8 a and an upper drain electrode 8 b.

The lower source line 9 a, the lower source electrode 7 a, the lowerdrain electrode 8 a, and the source terminal 10 are formed on the gateinsulating film 6. The lower source electrode 7 a and the lower drainelectrode 8 a are formed to be superimposed on the gate electrode 2, butare arranged to be separated from each other. A channel region of theTFT 201 is formed on the region between the lower source electrode 7 aand the lower drain electrode 8 a.

In FIG. 8, the source line 9 (the lower source line 9 a and the uppersource line 9 b) extends in the longitudinal direction. The lower sourceelectrode 7 a is formed to be connected to the lower source line 9 a.Specifically, the portion branched from the lower source line 9 a andextending to the TFT portion serves as the lower source electrode 7 a.

A semiconductor film 12 is formed to extend over the lower sourceelectrode 7 a and the lower drain electrode 8 a (i.e., the semiconductorfilm 12 is also formed on the region between the lower source electrode7 a and the lower drain electrode 8 a). The lower surface of thesemiconductor film 12 is in contact with the lower source electrode 7 aand the lower drain electrode 8 a, whereby the lower source electrode 7a and the lower drain electrode 8 a are both electrically connected tothe semiconductor film 12. The semiconductor film 12 is formed in anisland shape, and the portion located between the lower source electrode7 a and the lower drain electrode 8 a serves as the channel region 13.

In the present preferred embodiment, an oxide semiconductor is used asthe semiconductor film 12. More specifically, examples of a usable oxidesemiconductor include an oxide semiconductor of zinc oxide (ZnO), and anInGaZnO oxide semiconductor formed by adding gallium oxide (Ga₂O₃) andindium oxide (In₂O₃) to zinc oxide (ZnO). Since the channel region 13 ofthe semiconductor film 12 is made of the oxide semiconductor, mobilityhigher than that of a semiconductor film using amorphous silicon can berealized.

The protection insulating film 14 is formed on the entire upper surfaceof the substrate 1 so as to cover the semiconductor film 12, the lowersource line 9 a, the lower source electrode 7 a, the lower drainelectrode 8 a, and the source terminal 10. In the present preferredembodiment, the protection insulating film 30 is stacked on theprotection insulating film 14, and the channel region 13 of the TFT 201is protected by these protection insulating films 14 and 30. The upperprotection insulating film 30 is made of an organic resin film, and thisfilm flattens the upper surface of the substrate 1. The protectioninsulating film 30 is referred to as a “flattening film” hereinbelow.

A plurality of contact holes are formed on the protection insulatingfilm 14 and the flattening film 30. Specifically, the plurality ofcontact holes include a contact hole 16 reaching the lower source line 9a, contact holes 15 and 17 reaching the semiconductor film 12, and acontact hole 18 reaching the lower drain electrode 8 a.

The contact hole 15 is formed on the position where it is superimposedon the lower source electrode 7 a, and the contact hole 17 is formed onthe position where it is superimposed on the lower drain electrode 8 a.Accordingly, the contact holes 15 and 17 are formed on the positionswhere they are not superimposed on the channel region 13. The contactholes 16 are formed along the source line 9 with a constant interval asillustrated in FIG. 8.

The upper source line 9 b, the upper source electrode 7 b, the upperdrain electrode 8 b, and the pixel electrode 11 are formed on theflattening film 30.

The upper source electrode 7 b is formed to be connected to the uppersource line 9 b. Specifically, the portion branched from the uppersource line 9 b and extending to the TFT portion serves as the lowersource electrode 7 a. The upper source line 9 b is in contact with thelower source line 9 a through the contact hole 16, whereby the lowersource line 9 a and the upper source line 9 b are electricallyconnected. The upper source electrode 7 b is in contact with thesemiconductor film 12 above the lower source electrode 7 a through thecontact hole 15, whereby the semiconductor film 12 and the upper sourceelectrode 7 b are electrically connected. Accordingly, the semiconductorfilm 12 and the source line 9 are electrically connected through thelower source electrode 7 a, and electrically connected through the uppersource electrode 7 b.

The upper drain electrode 8 b is in contact with the semiconductor film12 above the lower drain electrode 8 a through the contact hole 17,whereby the semiconductor film 12 and the upper drain electrode 8 b areelectrically connected. The upper drain electrode 8 b is also in contactwith the lower drain electrode 8 a through the contact hole 18, wherebythe lower drain electrode 8 a and the upper drain electrode 8 b areelectrically connected.

The pixel electrode 11 is a plate electrode, and it is formed to beconnected to the upper drain electrode 8 b. Specifically, the portion ofthe pixel electrode 11 superimposed on the gate electrode 2 serves asthe upper drain electrode 8 b. Since the upper drain electrode 8 b iselectrically connected to the lower drain electrode 8 a, thesemiconductor film 12 and the pixel electrode 11 are electricallyconnected through the lower drain electrode 8 a, and also electricallyconnected through the upper drain electrode 8 b. In addition, the pixelelectrode 11 is locally superimposed on the auxiliary capacitanceelectrode 5 through the gate insulating film 6, the protectioninsulating film 14, and the flattening film 30, and the auxiliarycapacitance 209 is formed on this portion. In the transmissive liquidcrystal display, the pixel electrode 11 is made of a translucentconductive film.

An interlayer insulating film 31 is formed on the entire upper surfaceof the substrate 1 to cover the upper source line 9 b, the upper sourceelectrode 7 b, the upper drain electrode 8 b, and the pixel electrode11. Contact holes including a contact hole 21 reaching the auxiliarycapacitance line 210, a contact hole 19 reaching the gate terminal 4,and a contact hole 20 reaching the source terminal 10 are formed on theinterlayer insulating film 31 (the contact hole 20 penetrates theinterlayer insulating film 31, the flattening film 30, and theprotection insulating film 14, and the contact holes 19 and 21 penetrateeven the gate insulating film 6).

The common electrode 27, the gate terminal pad 25, and the sourceterminal pad 26 are formed on the interlayer insulating film 31.

As illustrated in FIG. 8, the common electrode 27 is an interdigitalelectrode having a slit, and is arranged opposite to the pixel electrode11 via the interlayer insulating film 31. The common electrode 27 is incontact with the auxiliary capacitance line 210 through the contact hole21, whereby the common electrode 27 and the auxiliary capacitance line210 are electrically connected.

The gate terminal pad 25 is in contact with the gate terminal 4 throughthe contact hole 19, whereby the gate terminal pad 25 and the gateterminal 4 are electrically connected. The source terminal pad 26 is incontact with the source terminal 10 through the contact hole 20, wherebythe gate terminal pad 25 and the source terminal 10 are electricallyconnected.

Subsequently, a manufacturing method of the TFT substrate 200 accordingto the second preferred embodiment will be described with reference toFIGS. 10 to 15. The components in FIGS. 10 to 15 corresponding to thecomponents in FIG. 9 are identified by the same numerals.

Firstly, the substrate 1 is cleaned with cleaning liquid or pure water.In the present preferred embodiment, a glass substrate with a thicknessof 0.5 mm is used as the substrate 1. Then, a first conductive film thatis a material of the gate electrode 2 and the gate line 3 is formed onthe entire main surface of the cleaned substrate 1.

Examples of usable first conductive film include chrome (Cr), molybdenum(Mo), titanium (Ti), copper (Cu), tantalum (Ta), tungsten (W), aluminum(Al), and an alloy formed by adding a small amount of other elements tothese metals. The first conductive film may have a stacked structureincluding two or more layers made of these metals or alloy. Alow-resistance conductive film having a specific resistance value of notmore than 50 μΩcm can be formed by using these metals or alloy.

In the present preferred embodiment, an Mo film is used as the firstconductive film, and this Mo film is subjected to film formation to havea thickness of 200 nm by a sputtering method using Ar gas. Thereafter, aphotoresist material is applied on the Mo film to form a photoresistpattern by the first photolithography process, and then, the Mo film ispatterned by an etching process with the photoresist pattern being usedas a mask. In this preferred embodiment, wet etching using a solution(PAN chemical) containing phosphoric acid, acetic acid, and nitric acidis performed.

Thereafter, the photoresist pattern is removed. As a result, the gateline 3, the gate electrode 2, the auxiliary capacitance electrode 5, theauxiliary capacitance line 210, and the gate terminal 4 are formed onthe substrate 1 as illustrated in FIG. 10.

Next, the gate insulating film 6 is formed on the entire upper surfaceof the substrate 1. In the present preferred embodiment, an oxidesilicon film (SiO) serving as the gate insulating film 6 is formed byusing a chemical vapor deposition (CVD) method. In the present preferredembodiment, the oxide silicon film with a thickness of 300 nm is formedunder a substrate heating condition of about 300° C. Since the oxidesilicon film has low barrier property (blocking property) to impurityelements affecting the TFT characteristic, such as water content (H₂O),hydrogen (H₂), sodium (Na), and potassium (K), the gate insulating film6 may have a stacked structure including a nitride silicon film (SiN),which has excellent barrier property, as a lower layer of the oxidesilicon film, for example.

Thereafter, a second conductive film that is a material for the lowersource electrode 7 a and the lower drain electrode 8 a is formed on thegate insulating film 6. In the present preferred embodiment, atranslucent conductive film is used as the second conductive film.Examples of usable second conductive film include chrome (Cr),molybdenum (Mo), titanium (Ti), copper (Cu), tantalum (Ta), tungsten(W), aluminum (Al), and an alloy formed by adding a small amount ofother elements to these metals. The second conductive film may have astacked structure including two or more layers made of these metals oralloy. A low-resistance conductive film having a specific resistancevalue of not more than 50 μΩcm can be formed by using these metals oralloy.

In the present preferred embodiment, an ITO film (a mixture ratio ofindium oxide In₂O₃ and tin oxide SnO₂ is 90:10 (wt %), for example) isused as the second conductive film. An ITO film generally has a stablecrystal (polycrystalline) structure at room temperature. Here, the ITOfilm is formed with a sputtering method by using a gas containinghydrogen (H) into argon (Ar), e.g., a gas formed by mixing hydrogen (H₂)gas or water vapor (H₂O), whereby the ITO film with a thickness of 100nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the second photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using an oxalic acid solution can be usedfor this etching process.

Thereafter, the photoresist pattern is removed. As a result, the lowersource line 9 a, the lower source electrode 7 a, the lower drainelectrode 8 a, and the source terminal 10 are formed as illustrated inFIG. 11.

Then, the substrate 1 is heated at a temperature of 200° C. According tothis heat treatment, the ITO film in the amorphous state is crystallizedto become a polycrystalline ITO film. Since the ITO film in apolycrystalline state has excellent chemical stability, and is notdissolved into general etching chemical (containing oxalic acid) exceptfor aqua regia (hydrochloric acid+nitric acid), etching selectivity witha metal film formed thereon in the subsequent process can be assured.The temperature in the heat treatment for crystallizing the amorphousITO film has to be higher than at least a temperature (crystallizationtemperature) at which the crystallization of the amorphous ITO film isstarted. The crystallization temperature of an amorphous ITO film havinga general composition is about 150° C.

Next, an oxide semiconductor that is a material for the semiconductorfilm 12 is formed. In the present preferred embodiment, an oxide(InGaZnO) containing In, Ga, and Zn is used as the oxide semiconductor.Here, an InGaZnO target having an atomic composition ratio of In:Ga:Zn:Ois 1:1:1:4 is used, and the oxide semiconductor (InGaZnO film) is formedby a sputtering method using Ar gas.

In this case, the atomic composition ratio of oxygen is less than astoichiometric composition, so that an oxide film with insufficientoxygen ion (in the example described above, the composition ratio of Ois less than 4) is generally formed. Therefore, it is preferable thatthe sputtering is performed by adding oxygen gas (O₂) to Ar gas. In thepresent preferred embodiment, the InGaZnO film with a thickness of 50 nmis formed with the sputtering using a mixed gas formed by adding O₂ gasof 10% in a partial pressure percent to Ar gas. The InGaZnO film isformed to have an amorphous structure. The crystallization temperatureof the InGaZnO film having the amorphous structure is generally 500° C.or higher, so that the most part in the film keeps the amorphousstructure and is stabilized in this state at room temperature.

Next, a photoresist pattern is formed by the third photolithographyprocess, and the InGaZnO film is etched by using this pattern as a mask.Thereafter, the photoresist pattern is removed. As a result, thesemiconductor film 12 extending over the lower source electrode 7 a andthe lower drain electrode 8 a is formed as illustrated in FIG. 12.

During the etching process of the InGaZnO film having the amorphousstructure, wet etching using an oxalic acid solution can be employed.The lower source line 9 a, the lower source electrode 7 a, the lowerdrain electrode 8 a, and the source terminal 10, which are formed in theprevious process, are the crystallized ITO film, and they are not etchedby the oxalic acid solution. Therefore, these patterns are noteliminated.

The semiconductor film 12 made of the oxide semiconductor (InGaZnO film)is brought into contact with the lower source electrode 7 a and theupper source electrode 7 b made of ITO that is also the oxide in orderto electrically connect the semiconductor film 12 and the lower andupper source electrodes 7 a and 7 b. According to this configuration,the interface reaction (oxidation-reduction reaction) between thesemiconductor film 12 and the lower and upper source electrodes 7 a and7 b is prevented. Accordingly, the contact resistance (interfaceresistance) between the semiconductor film 12 and the lower and uppersource electrodes 7 a and 7 b can be suppressed low. Consequently, oncurrent and mobility of the TFT 201 can be increased, whereby an effectof enhancing the TFT characteristic can be obtained.

After the semiconductor film 12 is formed, the protection insulatingfilm 14 and the flattening film 30 are formed on the entire uppersurface of the substrate 1. In the present preferred embodiment, anoxide silicon (SiO) film with a thickness of 100 nm is formed by using achemical vapor deposition (CVD) method under the substrate heatingcondition of about 250° C. to form the protection insulating film 14. Inaddition, the flattening film 30 is formed by applying an organic resin.

A photoresist pattern is then formed by the fourth photolithographyprocess, and the flattening film 30 and the protection insulating film14 are etched by using this pattern as a mask, whereby the contact holes15 to 18 are simultaneously formed. A dry etching process using fluorinegas can be used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the contacthole 16 reaching the lower source line 9 a and the contact holes 15 and17 reaching the semiconductor film 12 are formed as illustrated in FIG.13.

In the present preferred embodiment, the protection insulating film 14is the oxide silicon film. However, the protection insulating film 14may have a stacked structure including a nitride silicon film, which hasexcellent barrier property, as an upper layer of the oxide silicon film,for example, since the oxide silicon film has low barrier property(blocking property) to impurity elements affecting the TFTcharacteristic, such as water content (H₂O), hydrogen (H₂), sodium (Na),and potassium (K). Alternatively, the protection insulating film 14 mayhave a single-layer structure of a silicon nitride film.

When the silicon nitride is used for the protection insulating film 14,a wedge might be formed during the formation of the contact holereaching the surface of the translucent conductive film by the dryetching using fluorine gas, and this wedge might cause an electricalconnection failure. The effective structure for preventing thegeneration of the wedge is such that the protection insulating film 14is formed to have a stacked structure having at least two layersincluding an upper silicon nitride film and a lower silicon nitridefilm, in which the lower silicon nitride film is formed to have asmaller absolute value of a film stress than the upper silicon nitridefilm. Specifically, the absolute value of the film stress of the lowersilicon nitride film is preferably set in the range of 150 MPa to 200MPa. When the N/Si ratio of the silicon nitride film is increased, theabsolute value of the film stress can be decreased, but the N/Si ratioof the upper silicon nitride film is desirably in the range of 1.1 to1.5. Alternatively, it is also effective that the protection insulatingfilm 14 is formed to have a single-layer structure of a silicon nitridefilm having a small absolute value of a film stress.

Since the generation of the wedge is prevented, stress is balancedduring the formation of the protection insulating film 14, whereby thefilm-forming condition that makes it difficult to generate the filmfloating is easy to be employed. Consequently, the film floating of theprotection insulating film 14 can be prevented.

Thereafter, a third conductive film that is the material for the uppersource electrode 7 b, the upper drain electrode 8 b, and the pixelelectrode 11 is formed. In the present preferred embodiment, atranslucent conductive film is formed as the third conductive film. AnITO film (a mixture ratio of indium oxide In₂O₃ and tin oxide SnO₂ is90:10 (wt %), for example) is used as the translucent conductive film.An ITO film generally has a stable crystal (polycrystalline) structureat room temperature. Here, the ITO film is formed with a sputteringmethod by using a gas containing hydrogen (H) into argon (Ar), e.g., agas formed by mixing hydrogen (H₂) gas or water vapor (H₂O), whereby theITO film with a thickness of 100 nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the fifth photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using a solution containing phosphoricacid+nitric acid+acetic acid is used for this etching process. In thiscase, since the semiconductor film 12 made of the oxide semiconductorformed in the previous process is covered by the protection insulatingfilm 14, the pattern of the semiconductor film 12 is not eliminated bythe etching for the translucent conductive film, whereby the selectiveetching can be carried out.

Thereafter, the photoresist pattern is removed. As a result, the uppersource line 9 b, the upper source electrode 7 b, the upper drainelectrode 8 b, and the pixel electrode 11 are formed as illustrated inFIG. 14.

Next, an oxide silicon film (SiO) serving as the interlayer insulatingfilm 31 is formed with the chemical vapor deposition (CVD) method. Inthe present preferred embodiment, the oxide silicon film with athickness of 300 nm is formed under a substrate heating condition ofabout 300° C. Since the oxide silicon film has low barrier property(blocking property) to impurity elements affecting the TFTcharacteristic, such as water content (H₂O), hydrogen (H₂), sodium (Na),and potassium (K), the interlayer insulating film 31 may have a stackedstructure including a nitride silicon film (SiN), which has excellentbarrier property, as a lower layer of the oxide silicon film, forexample.

A photoresist pattern is then formed by the sixth photolithographyprocess, and the interlayer insulating film 31, the flattening film 30,the protection insulating film 14, and the gate insulating film 6 areetched by using this pattern as a mask, whereby the contact holes 19 to21 are simultaneously formed. A dry etching process using fluorine gascan be used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the contacthole 21 reaching the auxiliary capacitance line 210, the contact hole 19reaching the gate terminal 4, and the contact hole 20 reaching thesource terminal 10 are formed as illustrated in FIG. 15.

Thereafter, a fourth conductive film that is the material for the commonelectrode 27, the gate terminal pad 25, and the source terminal pad 26is formed. In the present preferred embodiment, a translucent conductivefilm is formed as the fourth conductive film. An ITO film (a mixtureratio of indium oxide In₂O₃ and tin oxide SnO₂ is 90:10 (wt %), forexample) is used for the translucent conductive film. An ITO filmgenerally has a stable crystal (polycrystalline) structure at roomtemperature. Here, the ITO film is formed with a sputtering method byusing a gas containing hydrogen (H) into argon (Ar), e.g., a gas formedby mixing hydrogen (H₂) gas or water vapor (H₂O), whereby the ITO filmwith a thickness of 100 nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the seventh photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using a solution containing phosphoricacid+nitric acid+acetic acid is used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the commonelectrode 27, the gate terminal pad 25, and the source terminal pad 26are formed. Thus, the structure illustrated in FIG. 9 is completed.

As described above, in the second preferred embodiment, thehigh-performance TFT substrate 200 in which the oxide semiconductor isused for the semiconductor film 12 in the TFT 201 can be formed by sevenphotolithography processes.

Upon assembling the liquid crystal display panel, an orientation filmand a spacer are formed on the surface of the completed TFT substrate200. The orientation film is a film for arraying the liquid crystal, andit is made of polyimide. A counter substrate that is separately formedto have a color filter or an orientation film is adhered to the TFTsubstrate 200. In this case, a gap is formed between the TFT substrate200 and the counter substrate by the spacer. The liquid crystal fillsthis gap, whereby the liquid crystal display panel is completed.Finally, a polarizing plate, a wave plate, and a backlight unit arearranged outside the liquid crystal display panel. Thus, a liquidcrystal display is completed.

In the present preferred embodiment, the semiconductor film 12 made ofan oxide semiconductor having weak chemical resistance is formed afterthe formation of the lower source electrode 7 a and the lower drainelectrode 8 a, and further, the ITO film that is the crystallized oxidetranslucent conductive film is used for the lower source electrode 7 aand the lower drain electrode 8 a. According to this structure, thesemiconductor film 12 that is the oxide semiconductor film canselectively be etched. In addition, the semiconductor film 12 and thelower source electrode 7 a as well as the lower drain electrode 8 a,which are made of oxide, are brought into contact with each other,whereby the semiconductor film 12 and the lower source electrode 7 a,and the semiconductor film 12 and the lower drain electrode 8 a areelectrically connected. Accordingly, the interface reaction(oxidation-reduction reaction) of these components can be prevented, andthe interface resistance can be suppressed low.

After the formation of the semiconductor film 12, the protectioninsulating film 14 and the flattening film 30 are formed to cover thesemiconductor film 12 that is the oxide semiconductor film, and thesemiconductor film 12 and the upper source electrode 7 b as well as theupper drain electrode 8 b are electrically connected through the contactholes 15 and 17 formed on the protection insulating film 14 and theflattening film 30. Specifically, the source electrode 7 and the drainelectrode 8 are electrically connected to both the upper and lowersurfaces of the semiconductor film 12. Accordingly, even if theinterface resistance between the semiconductor film 12 and the sourceelectrode 7 or the drain electrode 8 is defective on one of the surfacesof the semiconductor film 12, such defect can be compensated on theother surface. Consequently, the interface resistance can further bereduced, and the occurrence of defect caused by characteristic defect ofthe TFT 201 can be prevented.

In addition, the source line 9 includes two layers that are the lowersource line 9 a and the upper source line 9 b, in which the lower sourceline 9 a and the upper source line 9 b are electrically connected by theplurality of contact holes 16 formed on the protection insulating film14 and the flattening film 30 with a predetermined interval. Therefore,even if disconnection occurs on one of two layers, this can becompensated by the other one. Accordingly, the generation of defectcaused by the disconnection of the source line 9 can be prevented.

As described above, according to the present preferred embodiment, theinterface resistance between the semiconductor film 12 and the sourceelectrode 7 as well as the drain electrode 8 can be suppressed low, andthe generation of defect caused by the pattern failures of the lines caneffectively be prevented, even when an oxide semiconductor is used asthe semiconductor film 12 (channel layer) in the TFT 201. Since theoxide semiconductor having high mobility is used for the semiconductorfilm 12 in the TFT 201, the TFT substrate 200 having high operationspeed and a display device using the same can be manufactured with highyield. In other words, a high-performance TFT substrate and a liquidcrystal display can be manufactured with good productivity.

Third Preferred Embodiment

The second preferred embodiment describes the configuration in which theinterdigital common electrode having a slit is arranged above theplate-like pixel electrode. However, a configuration in which aninterdigital pixel electrode is arranged above a plate-like commonelectrode may be employed. In a third preferred embodiment, the casewhere the present invention is applied to a TFT substrate having thelatter configuration will be described.

FIGS. 16 and 17 are views illustrating a configuration of a TFTsubstrate 200 according to the third preferred embodiment. In thesedrawings, the components same as those in FIGS. 2 and 3 are identifiedby the same numerals.

FIG. 16 is a view illustrating a planar configuration of an essentialpart including a pixel 204 on the TFT substrate 200 using the FFSsystem, and FIG. 17 is a view illustrating its sectional configuration.FIG. 17 illustrates the sections corresponding to X-X line, Y-Y line,and Z-Z line in FIG. 16.

The section along X-X line corresponds to a formation region of thepixel 204 (pixel portion). The section along Y-Y line corresponds to aformation region of a gate terminal 4 and a gate terminal pad 25 (gateterminal portion), and the section along Z-Z line corresponds to aformation region of a source terminal 10 and a source terminal pad 26(source terminal portion). In addition, the section of the pixel portionalong X-X line includes a “gate/source line crossing portion” where agate line 3 and a source line 9 cross each other, a “TFT portion” thatis a formation region of the TFT 201, a “transmissive pixel portion”that is a formation region of a pixel electrode 11 and a commonelectrode 27, and an “auxiliary capacitance portion” that is a formationregion of auxiliary capacitance 209.

As illustrated in FIG. 17, the TFT substrate 200 is formed by using asubstrate 1 that is a transparent insulating substrate made of a glass,for example. The gate line 3, a gate electrode 2, an auxiliarycapacitance electrode 5, an auxiliary capacitance line 210, and the gateterminal 4 are formed on the substrate 1. A gate insulating film 6 isformed to cover these components.

In FIG. 16, the gate line 3 extends in the horizontal direction. Thegate electrode 2 on the TFT 201 is a part of the gate line 3.Specifically, the portion of the gate line 3 on the TFT portion servesas the gate electrode 2. The gate electrode 2 has a width larger thanthat of the other portion of the gate line 3. The gate terminal 4 isformed on one end of the gate line 3. The auxiliary capacitance line 210extends parallel to the gate line 3, and a part thereof serves as theauxiliary capacitance electrode 5.

As illustrated in FIG. 17, on the TFT substrate 200 according to thepresent preferred embodiment, each of the source line 9, a sourceelectrode 7, and a drain electrode 8 includes two layers, which areupper and lower layers, sandwiching a protection insulating film 14 anda flattening film 30. Specifically, the source line 9 includes a lowersource line 9 a and an upper source line 9 b, the source electrode 7includes a lower source electrode 7 a and an upper source electrode 7 b,and the drain electrode 8 includes a lower drain electrode 8 a and anupper drain electrode 8 b.

The lower source line 9 a, the lower source electrode 7 a, the lowerdrain electrode 8 a, and the source terminal 10 are formed on the gateinsulating film 6. The lower source electrode 7 a and the lower drainelectrode 8 a are formed to be superimposed on the gate electrode 2, butare arranged to be separated from each other. A channel region of theTFT 201 is formed on the region between the lower source electrode 7 aand the lower drain electrode 8 a.

In FIG. 16, the source line 9 (the lower source line 9 a and the uppersource line 9 b) extends in the longitudinal direction. The lower sourceelectrode 7 a is formed to be connected to the lower source line 9 a.Specifically, the portion branched from the lower source line 9 a andextending to the TFT portion serves as the lower source electrode 7 a.

A semiconductor film 12 is formed to extend over the lower sourceelectrode 7 a and the lower drain electrode 8 a (i.e., the semiconductorfilm 12 is also formed on the region between the lower source electrode7 a and the lower drain electrode 8 a). The lower surface of thesemiconductor film 12 is in contact with the lower source electrode 7 aand the lower drain electrode 8 a, whereby the lower source electrode 7a and the lower drain electrode 8 a are both electrically connected tothe semiconductor film 12. The semiconductor film 12 is formed in anisland shape, and the portion located between the lower source electrode7 a and the lower drain electrode 8 a serves as the channel region 13.

In the present preferred embodiment, an oxide semiconductor is used asthe semiconductor film 12. More specifically, examples of a usable oxidesemiconductor include an oxide semiconductor of zinc oxide (ZnO), and anInGaZnO oxide semiconductor formed by adding gallium oxide (Ga₂O₃) andindium oxide (In₂O₃) to zinc oxide (ZnO). Since the channel region 13 ofthe semiconductor film 12 is made of the oxide semiconductor, mobilityhigher than that of a semiconductor film using amorphous silicon can berealized.

The protection insulating film 14 and the flattening film 30 are formedon the entire upper surface of the substrate 1 so as to cover thesemiconductor film 12, the lower source line 9 a, the lower sourceelectrode 7 a, the lower drain electrode 8 a, and the source terminal10. The channel region 13 of the TFT 201 is protected by the protectioninsulating films 14 and 30.

A plurality of contact holes are formed on the protection insulatingfilm 14 and the flattening film 30. Specifically, the plurality ofcontact holes include a contact hole 16 reaching the lower source line 9a, contact holes 15 and 17 reaching the semiconductor film 12, a contacthole 18 reaching the lower drain electrode 8 a, and a contact hole 21reaching the auxiliary capacitance line 210 (the contact hole 21penetrates not only the flattening film 30 and the protection insulatingfilm 14 but also the gate insulating film 6).

The contact hole 15 is formed on the position where it is superimposedon the lower source electrode 7 a, and the contact hole 17 is formed onthe position where it is superimposed on the lower drain electrode 8 a.Accordingly, the contact holes 15 and 17 are formed on the positionswhere they are not superimposed on the channel region 13. The contactholes 16 are formed along the source line 9 with a constant interval asillustrated in FIG. 16.

The upper source line 9 b, the upper source electrode 7 b, the upperdrain electrode 8 b, and the common electrode 27 are formed on theflattening film 30.

The upper source electrode 7 b is formed to be connected to the uppersource line 9 b. Specifically, the portion branched from the uppersource line 9 b and extending to the TFT portion serves as the lowersource electrode 7 a. The upper source line 9 b is in contact with thelower source line 9 a through the contact hole 16, whereby the lowersource line 9 a and the upper source line 9 b are electricallyconnected. The upper source electrode 7 b is in contact with thesemiconductor film 12 above the lower source electrode 7 a through thecontact hole 15, whereby the semiconductor film 12 and the upper sourceelectrode 7 b are electrically connected. Accordingly, the semiconductorfilm 12 and the source line 9 are electrically connected through thelower source electrode 7 a, and electrically connected through the uppersource electrode 7 b.

The upper drain electrode 8 b is in contact with the semiconductor film12 above the lower drain electrode 8 a through the contact hole 17,whereby the semiconductor film 12 and the upper drain electrode 8 b areelectrically connected. The upper drain electrode 8 b is also in contactwith the lower drain electrode 8 a through the contact hole 18, wherebythe lower drain electrode 8 a and the upper drain electrode 8 b areelectrically connected.

The common electrode 27 is a plate electrode, and it is in contact withthe auxiliary capacitance line 210 through the contact hole 21, wherebythe common electrode 27 and the auxiliary capacitance line 210 areelectrically connected.

An interlayer insulating film 31 is formed on the entire upper surfaceof the substrate 1 to cover the upper source line 9 b, the upper sourceelectrode 7 b, the upper drain electrode 8 b, and the common electrode27. Contact holes including a contact hole 33 reaching the upper drainelectrode 8 b, a contact hole 19 reaching the gate terminal 4, and acontact hole 20 reaching the source terminal 10 are formed on theinterlayer insulating film 31 (the contact hole 20 penetrates theinterlayer insulating film 31, the flattening film 30, and theprotection insulating film 14, and the contact hole 21 penetrates eventhe gate insulating film 6).

The pixel electrode 11, the gate terminal pad 25, and the sourceterminal pad 26 are formed on the interlayer insulating film 31.

As illustrated in FIG. 16, the pixel electrode 11 is an interdigitalelectrode having a slit, and is arranged opposite to the commonelectrode 27 via the interlayer insulating film 31. The pixel electrode11 is in contact with the upper drain electrode 8 b through the contacthole 33, whereby the pixel electrode 11 and the upper drain electrode 8b are electrically connected. Since the upper drain electrode 8 b iselectrically connected to the lower drain electrode 8 a, thesemiconductor film 12 and the pixel electrode 11 are electricallyconnected through the lower drain electrode 8 a, and also electricallyconnected through the upper drain electrode 8 b. In the transmissiveliquid crystal display, the pixel electrode 11 is made of a translucentconductive film.

The gate terminal pad 25 is in contact with the gate terminal 4 throughthe contact hole 19, whereby the gate terminal pad 25 and the gateterminal 4 are electrically connected. The source terminal pad 26 is incontact with the source terminal 10 through the contact hole 20, wherebythe gate terminal pad 25 and the source terminal 10 are electricallyconnected.

Subsequently, a manufacturing method of the TFT substrate 200 accordingto the third preferred embodiment will be described with reference toFIGS. 18 to 23. The components in FIGS. 18 to 23 corresponding to thecomponents in FIG. 17 are identified by the same numerals.

Firstly, the substrate 1 is cleaned with cleaning liquid or pure water.In the present preferred embodiment, a glass substrate with a thicknessof 0.5 mm is used as the substrate 1. Then, a first conductive film thatis a material of the gate electrode 2 and the gate line 3 is formed onthe entire main surface of the cleaned substrate 1.

Examples of usable first conductive film include chrome (Cr), molybdenum(Mo), titanium (Ti), copper (Cu), tantalum (Ta), tungsten (W), aluminum(Al), and an alloy formed by adding a small amount of other elements tothese metals. The first conductive film may have a stacked structureincluding two or more layers made of these metals or alloy. Alow-resistance conductive film having a specific resistance value of notmore than 50 μΩcm can be formed by using these metals or alloy.

In the present preferred embodiment, an Mo film is used as the firstconductive film, and this Mo film is subjected to film formation to havea thickness of 200 nm by a sputtering method using Ar gas. Thereafter, aphotoresist material is applied on the Mo film to form a photoresistpattern by the first photolithography process, and then, the Mo film ispatterned by an etching process with the photoresist pattern being usedas a mask. In this preferred embodiment, wet etching using a solution(PAN chemical) containing phosphoric acid, acetic acid, and nitric acidis performed.

Thereafter, the photoresist pattern is removed. As a result, the gateline 3, the gate electrode 2, the auxiliary capacitance electrode 5, theauxiliary capacitance line 210, and the gate terminal 4 are formed onthe substrate 1 as illustrated in FIG. 18.

Next, the gate insulating film 6 is formed on the entire upper surfaceof the substrate 1. In the present preferred embodiment, an oxidesilicon film (SiO) serving as the gate insulating film 6 is formed byusing a chemical vapor deposition (CVD) method. In the present preferredembodiment, the oxide silicon film with a thickness of 300 nm is formedunder a substrate heating condition of about 300° C. Since the oxidesilicon film has low barrier property (blocking property) to impurityelements affecting the TFT characteristic, such as water content (H₂O),hydrogen (H₂), sodium (Na), and potassium (K), the gate insulating film6 may have a stacked structure including a nitride silicon film (SiN),which has excellent barrier property, as a lower layer of the oxidesilicon film, for example.

Thereafter, a second conductive film that is a material for the lowersource electrode 7 a and the lower drain electrode 8 a is formed on thegate insulating film 6. In the present preferred embodiment, atranslucent conductive film is used as the second conductive film.Examples of usable second conductive film include chrome (Cr),molybdenum (Mo), titanium (Ti), copper (Cu), tantalum (Ta), tungsten(W), aluminum (Al), and an alloy formed by adding a small amount ofother elements to these metals. The second conductive film may have astacked structure including two or more layers made of these metals oralloy. A low-resistance conductive film having a specific resistancevalue of not more than 50 μΩcm can be formed by using these metals oralloy.

In the present preferred embodiment, an ITO film (a mixture ratio ofindium oxide In₂O₃ and tin oxide SnO₂ is 90:10 (wt %), for example) isused as the second conductive film. An ITO film generally has a stablecrystal (polycrystalline) structure at room temperature. Here, the ITOfilm is formed with a sputtering method by using a gas containinghydrogen (H) into argon (Ar), e.g., a gas formed by mixing hydrogen (H₂)gas or water vapor (H₂O), whereby the ITO film with a thickness of 100nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the second photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using an oxalic acid solution can be usedfor this etching process.

Thereafter, the photoresist pattern is removed. As a result, the lowersource line 9 a, the lower source electrode 7 a, the lower drainelectrode 8 a, and the source terminal 10 are formed as illustrated inFIG. 19.

Then, the substrate 1 is heated at a temperature of 200° C. According tothis heat treatment, the ITO film in the amorphous state is crystallizedto become a polycrystalline ITO film. Since the ITO film in apolycrystalline state has excellent chemical stability, and is notdissolved into general etching chemical (containing oxalic acid) exceptfor aqua regia (hydrochloric acid+nitric acid), etching selectivity witha metal film formed thereon in the subsequent process can be assured.The temperature in the heat treatment for crystallizing the amorphousITO film has to be higher than at least a temperature (crystallizationtemperature) at which the crystallization of the amorphous ITO film isstarted. The crystallization temperature of an amorphous ITO film havinga general composition is about 150° C.

Next, an oxide semiconductor that is a material for the semiconductorfilm 12 is formed. In the present preferred embodiment, an oxide(InGaZnO) containing In, Ga, and Zn is used as the oxide semiconductor.Here, an InGaZnO target having an atomic composition ratio of In:Ga:Zn:Ois 1:1:1:4 is used, and the oxide semiconductor (InGaZnO film) is formedby a sputtering method using Ar gas.

In this case, the atomic composition ratio of oxygen is less than astoichiometric composition, so that an oxide film with insufficientoxygen ion (in the example described above, the composition ratio of Ois less than 4) is generally formed. Therefore, it is preferable thatthe sputtering is performed by adding oxygen gas (O₂) to Ar gas. In thepresent preferred embodiment, the InGaZnO film with a thickness of 50 nmis formed with the sputtering using a mixed gas formed by adding O₂ gasof 10% in a partial pressure percent to Ar gas. The InGaZnO film isformed to have an amorphous structure. The crystallization temperatureof the InGaZnO film having the amorphous structure is generally 500° C.or higher, so that the most part in the film keeps the amorphousstructure and is stabilized in this state at room temperature.

Next, a photoresist pattern is formed by the third photolithographyprocess, and the InGaZnO film is etched by using this pattern as a mask.Thereafter, the photoresist pattern is removed. As a result, thesemiconductor film 12 extending over the lower source electrode 7 a andthe lower drain electrode 8 a is formed as illustrated in FIG. 20.

During the etching process of the InGaZnO film having the amorphousstructure, wet etching using an oxalic acid solution can be employed.The lower source line 9 a, the lower source electrode 7 a, the lowerdrain electrode 8 a, and the source terminal 10, which are formed in theprevious process, are the crystallized ITO film, and they are not etchedby the oxalic acid solution. Therefore, these patterns are noteliminated.

The semiconductor film 12 made of the oxide semiconductor (InGaZnO film)is brought into contact with the lower source electrode 7 a and theupper source electrode 7 b made of ITO that is also the oxide in orderto electrically connect the semiconductor film 12 and the lower andupper source electrodes 7 a and 7 b. According to this configuration,the interface reaction (oxidation-reduction reaction) between thesemiconductor film 12 and the lower and upper source electrodes 7 a and7 b is prevented. Accordingly, the contact resistance (interfaceresistance) between the semiconductor film 12 and the lower and uppersource electrodes 7 a and 7 b can be suppressed low. Consequently, oncurrent and mobility of the TFT 201 can be increased, whereby an effectof enhancing the TFT characteristic can be obtained.

After the semiconductor film 12 is formed, the protection insulatingfilm 14 and the flattening film 30 are formed on the entire uppersurface of the substrate 1. In the present preferred embodiment, anoxide silicon (SiO) film with a thickness of 100 nm is formed by using achemical vapor deposition (CVD) method under the substrate heatingcondition of about 250° C. to form the protection insulating film 14. Inaddition, the flattening film 30 is formed by applying an organic resin.

A photoresist pattern is then formed by the fourth photolithographyprocess, and the flattening film 30 and the protection insulating film14 are etched by using this pattern as a mask, whereby the contact holes15 to 18 and 21 are simultaneously formed. A dry etching process usingfluorine gas can be used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the contacthole 16 reaching the lower source line 9 a, the contact holes 15 and 17reaching the semiconductor film 12, and the contact hole 21 reaching theauxiliary capacitance line 210 are formed as illustrated in FIG. 21.

In the present preferred embodiment, the protection insulating film 14is the oxide silicon film. However, the protection insulating film 14may have a stacked structure including a nitride silicon film, which hasexcellent barrier property, as an upper layer of the oxide silicon film,for example, since the oxide silicon film has low barrier property(blocking property) to impurity elements affecting the TFTcharacteristic, such as water content (H₂O), hydrogen (H₂), sodium (Na),and potassium (K). Alternatively, the protection insulating film 14 mayhave a single-layer structure of a silicon nitride film.

When the silicon nitride is used for the protection insulating film 14,a wedge might be formed during the formation of the contact holereaching the surface of the translucent conductive film by the dryetching using fluorine gas, and this wedge might cause an electricalconnection failure. The effective structure for preventing thegeneration of the wedge is such that the protection insulating film 14is formed to have a stacked structure having at least two layersincluding an upper silicon nitride film and a lower silicon nitridefilm, in which the lower silicon nitride film is formed to have asmaller absolute value of a film stress than the upper silicon nitridefilm. Specifically, the absolute value of the film stress of the lowersilicon nitride film is preferably set in the range of 150 MPa to 200MPa. When the N/Si ratio of the silicon nitride film is increased, theabsolute value of the film stress can be decreased, but the N/Si ratioof the upper silicon nitride film is desirably in the range of 1.1 to1.5. Alternatively, it is also effective that the protection insulatingfilm 14 is formed to have a single-layer structure of a silicon nitridefilm having a small absolute value of a film stress.

Since the generation of the wedge is prevented, stress is balancedduring the formation of the protection insulating film 14, whereby thefilm-forming condition that makes it difficult to generate the filmfloating is easy to be employed. Consequently, the film floating of theprotection insulating film 14 can be prevented.

Thereafter, a third conductive film that is the material for the uppersource electrode 7 b, the upper drain electrode 8 b, and the commonelectrode 27 is formed. In the present preferred embodiment, atranslucent conductive film is formed as the third conductive film. AnITO film (a mixture ratio of indium oxide In₂O₃ and tin oxide SnO₂ is90:10 (wt %), for example) is used as the translucent conductive film.An ITO film generally has a stable crystal (polycrystalline) structureat room temperature. Here, the ITO film is formed with a sputteringmethod by using a gas containing hydrogen (H) into argon (Ar), e.g., agas formed by mixing hydrogen (H₂) gas or water vapor (H₂O), whereby theITO film with a thickness of 100 nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the fifth photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using a solution containing phosphoricacid+nitric acid+acetic acid is used for this etching process. In thiscase, since the semiconductor film 12 made of the oxide semiconductorformed in the previous process is covered by the protection insulatingfilm 14, the pattern of the semiconductor film 12 is not eliminated bythe etching for the translucent conductive film, whereby the selectiveetching can be carried out.

Thereafter, the photoresist pattern is removed. As a result, the uppersource line 9 b, the upper source electrode 7 b, the upper drainelectrode 8 b, and the common electrode 27 are formed as illustrated inFIG. 22.

Next, an oxide silicon film (SiO) serving as the interlayer insulatingfilm 31 is formed with the chemical vapor deposition (CVD) method. Inthe present preferred embodiment, the oxide silicon film with athickness of 300 nm is formed under a substrate heating condition ofabout 300° C. Since the oxide silicon film has low bather property(blocking property) to impurity elements affecting the TFTcharacteristic, such as water content (H₂O), hydrogen (H₂), sodium (Na),and potassium (K), the interlayer insulating film 31 may have a stackedstructure including a nitride silicon film (SiN), which has excellentbarrier property, as a lower layer of the oxide silicon film, forexample.

When the silicon nitride is used for the interlayer insulating film 31,a wedge might be formed during the formation of the contact holereaching the surface of the translucent conductive film by the dryetching using fluorine gas, and this wedge might cause an electricalconnection failure. The effective structure for preventing thegeneration of the wedge is such that the interlayer insulating film 31is formed to have a stacked structure having at least two layersincluding an upper silicon nitride film and a lower silicon nitridefilm, in which the lower silicon nitride film is formed to have asmaller absolute value of a film stress than the upper silicon nitridefilm. Specifically, the absolute value of the film stress of the lowersilicon nitride film is preferably set in the range of 150 MPa to 200MPa. When the N/Si ratio of the silicon nitride film is increased, theabsolute value of the film stress can be decreased, but the N/Si ratioof the upper silicon nitride film is desirably in the range of 1.1 to1.5. Alternatively, it is also effective that the interlayer insulatingfilm 31 is formed to have a single-layer structure of a silicon nitridefilm having a small absolute value of a film stress.

Since the generation of the wedge is prevented, stress is balancedduring the formation of the interlayer insulating film 31, whereby thefilm-forming condition that makes it difficult to generate the filmfloating is easy to be employed. Consequently, the film floating of theinterlayer insulating film 31 can be prevented.

A photoresist pattern is then formed by the sixth photolithographyprocess, and the interlayer insulating film 31, the flattening film 30,the protection insulating film 14, and the gate insulating film 6 areetched by using this pattern as a mask, whereby the contact holes 19,20, and 33 are simultaneously formed. A dry etching process usingfluorine gas can be used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the contacthole 33 reaching the upper drain electrode 8 b, the contact hole 19reaching the gate terminal 4, and the contact hole 20 reaching thesource terminal 10 are formed as illustrated in FIG. 23.

Thereafter, a fourth conductive film that is the material for the pixelelectrode 11, the gate terminal pad 25, and the source terminal pad 26is formed. In the present preferred embodiment, a translucent conductivefilm is formed as the fourth conductive film. An ITO film (a mixtureratio of indium oxide In₂O₃ and tin oxide SnO₂ is 90:10 (wt %), forexample) is used as the translucent conductive film. An ITO filmgenerally has a stable crystal (polycrystalline) structure at roomtemperature. Here, the ITO film is formed with a sputtering method byusing a gas containing hydrogen (H) into argon (Ar), e.g., a gas formedby mixing hydrogen (H₂) gas or water vapor (H₂O), whereby the ITO filmwith a thickness of 100 nm is formed in an amorphous state.

Then, a photoresist pattern is formed by the seventh photolithographyprocess, and the amorphous ITO film is etched by using the photoresistpattern as a mask. Wet etching using a solution containing phosphoricacid+nitric acid+acetic acid is used for this etching process.

Thereafter, the photoresist pattern is removed. As a result, the pixelelectrode 11, the gate terminal pad 25, and the source terminal pad 26are formed. Thus, the structure illustrated in FIG. 17 is completed.

As described above, in the third preferred embodiment, thehigh-performance TFT substrate 200 in which the oxide semiconductor isused for the semiconductor film 12 in the TFT 201 can be formed by sevenphotolithography processes.

Upon assembling the liquid crystal display panel, an orientation filmand a spacer are formed on the surface of the completed TFT substrate200. The orientation film is a film for arraying the liquid crystal, andit is made of polyimide. A counter substrate that is separately formedto have a color filter or an orientation film is adhered to the TFTsubstrate 200. In this case, a gap is formed between the TFT substrate200 and the counter substrate by the spacer. The liquid crystal fillsthis gap, whereby the liquid crystal display panel is completed.Finally, a polarizing plate, a wave plate, and a backlight unit arearranged outside the liquid crystal display panel. Thus, a liquidcrystal display is completed.

In the present preferred embodiment, the semiconductor film 12 made ofan oxide semiconductor having weak chemical resistance is formed afterthe formation of the lower source electrode 7 a and the lower drainelectrode 8 a, and further, the ITO film that is the crystallized oxidetranslucent conductive film is used for the lower source electrode 7 aand the lower drain electrode 8 a. According to this structure, thesemiconductor film 12 that is the oxide semiconductor film canselectively be etched. In addition, the semiconductor film 12 and thelower source electrode 7 a as well as the lower drain electrode 8 a,which are made of oxide, are brought into contact with each other,whereby the semiconductor film 12 and the lower source electrode 7 a,and the semiconductor film 12 and the lower drain electrode 8 a areelectrically connected. Accordingly, the interface reaction(oxidation-reduction reaction) of these components can be prevented, andthe interface resistance can be suppressed low.

After the formation of the semiconductor film 12, the protectioninsulating film 14 and the flattening film 30 are formed to cover thesemiconductor film 12 that is the oxide semiconductor film, and thesemiconductor film 12 and the upper source electrode 7 b as well as theupper drain electrode 8 b are electrically connected through the contactholes 15 and 17 formed on the protection insulating film 14 and theflattening film 30. Specifically, the source electrode 7 and the drainelectrode 8 are electrically connected to both the upper and lowersurfaces of the semiconductor film 12. Accordingly, even if theinterface resistance between the semiconductor film 12 and the sourceelectrode 7 or the drain electrode 8 is defective on one of the surfacesof the semiconductor film 12, such defect can be compensated on theother surface. Consequently, the interface resistance can further bereduced, and the occurrence of defect caused by characteristic defect ofthe TFT 201 can be prevented.

In addition, the source line 9 includes two layers that are the lowersource line 9 a and the upper source line 9 b, in which the lower sourceline 9 a and the upper source line 9 b are electrically connected by theplurality of contact holes 16 formed on the protection insulating film14 and the flattening film 30 with a predetermined interval. Therefore,even if disconnection occurs on one of two layers, this can becompensated by the other one. Accordingly, the generation of defectcaused by the disconnection of the source line 9 can be prevented.

As described above, according to the present preferred embodiment, theinterface resistance between the semiconductor film 12 and the sourceelectrode 7 as well as the drain electrode 8 can be suppressed low, andthe generation of defect caused by the pattern failures of the lines caneffectively be prevented, even when an oxide semiconductor is used asthe semiconductor film 12 (channel layer) in the TFT 201. Since theoxide semiconductor having high mobility is used for the semiconductorfilm 12 in the TFT 201, the TFT substrate 200 having high operationspeed and a display device using the same can be manufactured with highyield. In other words, a high-performance TFT substrate, and a liquidcrystal display can be manufactured with good productivity.

While the invention has been shown and described in detail, theforegoing description is in all aspects illustrative and notrestrictive. It is therefore understood that numerous modifications andvariations can be devised without departing from the scope of theinvention.

What is claimed is:
 1. A manufacturing method of a thin film transistorsubstrate comprising the steps of: (a) forming a gate electrode and anauxiliary capacitance electrode on a substrate by using a firstconductive film; (b) forming a first insulating film to cover said gateelectrode and said auxiliary capacitance electrode; (c) forming a lowersource electrode, a lower drain electrode, and a pixel electrodeconnected to said lower drain electrode on said first insulating film byusing a second conductive film; (d) forming a semiconductor film, whichis electrically connected to said lower source electrode and said lowerdrain electrode, on said lower source electrode and said lower drainelectrode; (e) forming a second insulating film on said lower sourceelectrode, said lower drain electrode, and said semiconductor film; and(f) forming an upper source electrode electrically connected to saidsemiconductor film and said lower source electrode through a contacthole, an upper drain electrode electrically connected to saidsemiconductor film and said lower drain electrode through a contacthole, and a common electrode electrically connected to said auxiliarycapacitance electrode through a contact hole, the upper sourceelectrode, the upper drain electrode, and the common electrode beingformed on said second insulating film by using a third conductive film.2. A manufacturing method of a thin film transistor substrate comprisingthe steps of: (a) forming a gate electrode and an auxiliary capacitanceelectrode on a substrate by using a first conductive film; (b) forming afirst insulating film to cover said gate electrode and said auxiliarycapacitance electrode; (c) forming a lower source electrode and a lowerdrain electrode on said first insulating film by using a secondconductive film; (d) forming a semiconductor film, which is electricallyconnected to said lower source electrode and said lower drain electrode,on said lower source electrode and said lower drain electrode; (e)forming a second insulating film on said lower source electrode, saidlower drain electrode, and said semiconductor film; (f) forming an uppersource electrode electrically connected to said semiconductor film andsaid lower source electrode through a contact hole, an upper drainelectrode electrically connected to said semiconductor film and saidlower drain electrode through a contact hole, and a pixel electrodeconnected to said upper drain electrode, the upper source electrode, theupper drain electrode, and the pixel electrode being formed on saidsecond insulating film by using a third conductive film; (g) forming athird insulating film on said upper source electrode, said upper drainelectrode, and said pixel electrode; and (h) forming a common electrode,which is electrically connected to said auxiliary capacitance electrodethrough a contact hole, on said third insulating film.
 3. Amanufacturing method of a thin film transistor substrate comprising thesteps of: (a) forming a gate electrode and an auxiliary capacitanceelectrode on a substrate by using a first conductive film; (b) forming afirst insulating film to cover said gate electrode and said auxiliarycapacitance electrode; (c) forming a lower source electrode and a lowerdrain electrode on said first insulating film by using a secondconductive film; (d) forming a semiconductor film, which is electricallyconnected to said lower source electrode and said lower drain electrode,on said lower source electrode and said lower drain electrode; (e)forming a second insulating film on said lower source electrode, saidlower drain electrode, and said semiconductor film; (f) forming an uppersource electrode electrically connected to said semiconductor film andsaid lower source electrode through a contact hole, an upper drainelectrode electrically connected to said semiconductor film and saidlower drain electrode through a contact hole, and a common electrodeelectrically connected to said auxiliary capacitance electrode through acontact hole, the upper source electrode, the upper drain electrode, andthe common electrode being formed on said second insulating film byusing a third conductive film; (g) forming a third insulating film onsaid upper source electrode, said upper drain electrode, and said commonelectrode; and (h) forming a pixel electrode, which is electricallyconnected to said upper drain electrode through a contact hole, on saidthird insulating film.